CPI T02KO User manual

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INSTALLATION
&
OPERATION
MANUAL
250W Ka-Band TWT Amplifier
For Use With Model Numbers . . .
T02KO
T03KO
Service Center Headquarters and Design Center
West Coast Operations
811 Hansen Way
Palo Alto, CA 94303
Manufacturing
East Coast Operations
45 River Drive
Georgetown, ON Canada L7G 2J4

PROPRIETARY INFORMATION
The design and other information contained in this document are provided solely for the
purposes of operating and maintaining CPI equipment. Except for rights expressly granted by
contract, all such information is the exclusive property of CPI Satcom Division. This document
may not be duplicated, in whole or in part, or be used for manufacture without written
permission of CPI, Satcom Division.
Copyright @ 2007 by Communications & Power Industries. All rights reserved.
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Table of Contents
CHAPTER Safety ........................................................................................................................................S-1
S.1 Introduction......................................................................................................................................S-1
S.2 High Voltage Equipment.................................................................................................................S-1
S.2.1 Personnel Operating Guidelines................................................................................................S-1
S.2.2 When is Voltage "High"?...........................................................................................................S-2
S.2.3 General High Voltage Guidelines..............................................................................................S-2
S.3 Microwave Radiation.......................................................................................................................S-5
S.3.1 Personnel Operating Guidelines................................................................................................S-5
S.3.2 Microwave Discussion...............................................................................................................S-5
S.3.3 General Microwave Guidelines .................................................................................................S-6
S.4 Physical Safety..................................................................................................................................S-7
S.4.1 Lifting Heavy Objects.................................................................................................................S-7
S.4.2 Extending Rack Slides................................................................................................................S-7
CHAPTER 1 Introduction..........................................................................................................................1-1
1.1 Overview...........................................................................................................................................1-1
1.2 Optional Features.............................................................................................................................1-3
1.3 About This Manual..........................................................................................................................1-3
1.4 Conventions......................................................................................................................................1-4
1.4.1 Notes and Cautions....................................................................................................................1-4
1.4.2 Warnings....................................................................................................................................1-5
1.4.3 Text Conventions........................................................................................................................1-5
CHAPTER 2 Unpacking And Installation.................................................................................................2-1
2.1 Overview...........................................................................................................................................2-1
2.2 Pre-Inspection ..................................................................................................................................2-1
2.3 Unpacking.........................................................................................................................................2-1
2.4 Installation........................................................................................................................................2-1
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2.4.1
Amplifier Installation.................................................................................................................2-2
2.4.2 Cooling Considerations .............................................................................................................2-2
2.4.3 Electrical Power Connections ...................................................................................................2-3
2.4.3.1 Prime Power (J1)....................................................................................................................2-3
2.4.3.2 Grounding ..............................................................................................................................2-3
2.4.4 Remote Control Interface (J6) ...................................................................................................2-4
2.4.5 Switch Interface Connector (J5) ................................................................................................2-5
2.4.6 RF Coaxial Cable Connections (J4)..........................................................................................2-5
2.4.7 RF Input Waveguide Flange Connection (J3) ...........................................................................2-6
2.4.8 RF Output Waveguide Flange Connection (J8).........................................................................2-6
CHAPTER 3 Initial Power On And Checkout.........................................................................................3-1
3.1 Overview...........................................................................................................................................3-1
3.2 Front Panel Controls and Indicators .............................................................................................3-2
3.3 Optional RCU Controls and Indicators.........................................................................................3-4
3.3.1 Multi-Drop Operation................................................................................................................3-4
3.3.3.1 Amplifier Address Assignment..............................................................................................3-4
3.3.1.2 Operational Summary of the Remote Control Unit (RCU)....................................................3-5
3.3.2 Control Keys ..............................................................................................................................3-7
3.3.3 LED Group and Display...........................................................................................................3-8
3.4 Operation with PC Computer and Setup & Remote Control Software....................................3-11
3.5 Operation with Ethernet ...............................................................................................................3-12
3.6 First Time Pre-Power Procedure..................................................................................................3-12
3.7 Power-On Sequence.......................................................................................................................3-13
3.7.1 Initial Check, High Voltage OFF.............................................................................................3-13
3.7.1.1 Check Factory Set Values via a Computer ..........................................................................3-14
3.7.1.2 Check Factory Set Values via RCU.....................................................................................3-14
3.7.2 Initial Check, High Voltage ON...............................................................................................3-18
3.8 Verify RF Output...........................................................................................................................3-19
3.9 Setup for Operational Service.......................................................................................................3-20
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4.1 Overview...........................................................................................................................................4-1
4.1.1 Control Mode Hierarchy............................................................................................................4-1
4.2 Serial Interface.................................................................................................................................4-1
4.2.1 Interface Configuration..............................................................................................................4-1
4.3 RF Switch Interface (J5)..................................................................................................................4-2
4.3.1 Relay Definitions........................................................................................................................4-2
4.4 Ethernet Interface............................................................................................................................4-6
4.4.1 IP Setup......................................................................................................................................4-7
4.4.2 Web Interface.............................................................................................................................4-9
4.4.3 Configuring Email ...................................................................................................................4-10
4.4.4 Changing the Login..................................................................................................................4-11
4.4.5 Amplifier Information ..............................................................................................................4-12
4.4.6 Download / Upload Files using FTP.......................................................................................4-13
4.4.7 Firmware updates....................................................................................................................4-14
4.4.8 LAN Interface Port Numbers ...................................................................................................4-15
4.5 JAVA CIF Remote Program.........................................................................................................4-16
Java JRE ..................................................................................................................................................4-16
4.5.1 Running CIF Remote: ..............................................................................................................4-16
4.5.2 Meters ......................................................................................................................................4-18
4.5.3 Setup.........................................................................................................................................4-19
4.5.4 Settings.....................................................................................................................................4-20
4.5.5 Engineering..............................................................................................................................4-21
4.5.6 Configuration...........................................................................................................................4-22
4.5.7 Meter Log.................................................................................................................................4-23
4.5.8 Switch System...........................................................................................................................4-24
CHAPTER 5 Normal Operation ................................................................................................................5-1
5.1 General..............................................................................................................................................5-1
5.2 Overview of Operation ....................................................................................................................5-2
5.3 Normal Operating Procedures........................................................................................................5-2
5.3.1 LOCAL Mode Operation............................................................................................................5-2
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5.3.2 Remote Control Mode, Computer Control.................................................................................5-3
5.4 Shutdown..........................................................................................................................................5-3
5.4.1 Normal Shutdown.......................................................................................................................5-3
5.4.2 Prime Power Interrupts .............................................................................................................5-4
5.5 Making Routine Safety Checks.......................................................................................................5-4
5.6 Description of Amplifier States.......................................................................................................5-4
5.6.1 Post ............................................................................................................................................5-5
5.6.2 Heater Time Delay (HTD) .........................................................................................................5-5
5.6.3 Standby State..............................................................................................................................5-5
5.6.4 Beam On Sequence.....................................................................................................................5-6
5.6.5 Transmit State............................................................................................................................5-6
5.6.6 Beam Off Sequence ....................................................................................................................5-6
5.6.7 Fault State..................................................................................................................................5-6
5.6.7.1 Auto Fault Recycle Mode Rules............................................................................................5-6
5.6.7.2 Meter log...............................................................................................................................5-7
CHAPTER 6 Operator Maintenance.........................................................................................................6-1
6.1 Introduction......................................................................................................................................6-1
6.2 Preventive Maintenance Tasks.......................................................................................................6-1
6.2.1 Visual Inspection........................................................................................................................6-2
6.2.2 Air System Maintenance.............................................................................................................6-3
6.3 Other Preventive Maintenance Tasks............................................................................................6-4
6.4 Customer Service .............................................................................................................................6-4
CHAPTER 7 Drawings................................................................................................................................7-1
APPENDIX A Warranty And Support Information...............................................................................A-1
APPENDIX B.............................................................................................................................................. B-1
B.1 Introduction..................................................................................................................................... B-2
B.2 Installation....................................................................................................................................... B-2
B.2.1 Connecting to the Amplifier(s)...................................................................................................B-2
B.2.2 Meters Window ..........................................................................................................................B-4
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B.2.3 Settings Window.........................................................................................................................B-5
B.2.3.1 General.............................................................................................................................. B-5
B.2.3.2 Configuration.................................................................................................................... B-7
B.2.3.3 Engineering....................................................................................................................... B-7
B.2.3.4 CIF .................................................................................................................................... B-8
B.2.4 Meter Log...................................................................................................................................B-8
B.2.4.1 Auto Update...................................................................................................................... B-9
B.2.4.2 Auto Log Time.................................................................................................................. B-9
B.2.4.3 Search................................................................................................................................B-9
B.2.4.4 Save File............................................................................................................................ B-9
B.2.5 Switch Systems .........................................................................................................................B-11
B.2.5.1 Switch Configuration Diagrams...................................................................................... B-12
B.2.6 Alerts........................................................................................................................................B-15
B.2.6.1 Media Player................................................................................................................... B-15
B.2.6.2 Restore Window.............................................................................................................. B-16
B.2.6.3 Confirmation................................................................................................................... B-16
B.2.7 Tuning Screen Setup.................................................................................................................B-16
B.2.7.1 Millitron.......................................................................................................................... B-16
B.3 Troubleshooting.................................................................................................................................. B-17
B.3.1 Communication........................................................................................................................B-17
APPENDIX C Replaceable Parts ..............................................................................................................C-1
APPENDIX D Optional Linearizer...........................................................................................................D-1
D-1 Optional Linearizer ........................................................................................................................D-1
APPENDIX E 250w ODU Functional Trees............................................................................................. E-1
APPENDIX F Optional Internal 1:1 Switch Controller..........................................................................F-1
F.1 Optional Internal 1:1 Switch Controller........................................................................................F-1
F.2 Drawing List.....................................................................................................................................F-3
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List of Figures
FIGURE 1-1. KA-BAND TWTA (FRONT VIEW)______________________________________________1-2
FIGURE 1-2. TYPICAL KA-BAND TWTA RF DIAGRAM________________________________________1-3
FIGURE 2-1. KA-BAND TWTA CONNECTOR LOCATIONS _____________________________________2-4
FIGURE 2-2 RS-232 CABLES __________________________________________________________2-5
FIGURE2-3 KA-BAND TWTA REAR PANEL ______________________________________________2-7
FIGURE 3-1 AMPLIFIER FRONT PANEL CONTROLS AND INDICATORS ___________________________3-2
FIGURE 3-2. REMOTE CONTROL UNIT FRONT AND REAR PANELS _______________________________3-4
FIGURE 3-3. REMOTE CONTROL UNIT CONTROL KEYS________________________________________3-8
FIGURE 3-4. LED AND DISPLAY GROUP ___________________________________________________3-9
FIGURE 3-5. REMOTE CONTROL UNIT MENU TREE___________________________________________3-9
FIGURE 3-6-A. REMOTE CONTROL UNIT MENU TREE ________________________________________3-10
FIGURE 3-6-B. REMOTE CONTROL UNIT MENU TREE ________________________________________3-11
FIGURE 3-7. ETHERNET OPTION_________________________________________________________3-12
FIGURE B-1 STARTUP SCREENS_________________________________________________________ B-2
FIGURE B-2 CONFIGURATION SCREEN / AMPLIFIERS 1-5 TAB _________________________________ B-3
FIGURE B-2A CONFIGURATION SCREEN / INTERFACE TAB ____________________________________ B-3
FIGURE B-3 TYPICAL METER SCREEN____________________________________________________ B-4
FIGURE B-4 TYPICAL SETTING SCREEN / GENERAL TAB _____________________________________ B-6
FIGURE B-4A CONFIGURATION TAB _____________________________________________________ B-7
FIGURE B-4B ENGINEERING TAB ________________________________________________________ B-7
FIGURE B-4C CIF TAB ________________________________________________________________ B-8
FIGURE B-5 TYPICAL METER LOG SCREEN________________________________________________ B-8
FIGURE B-6 SAVE LOG FILE SCREENS___________________________________________________ B-10
FIGURE B-7 TYPICAL SWITCH DIAGRAM SCREEN__________________________________________ B-11
FIGURE B-8A 1:1A FIGURE B-8B 1:1B _____________________________________ B-12
FIGURE B-8C 1:1C __________________________________________________________________ B-12
FIGURE B-8D 1:1D-P ________________________________________________________________ B-12
FIGURE B-8E 1:1E __________________________________________________________________ B-13
FIGURE B-8F 1:1E-P_________________________________________________________________ B-13
FIGURE B-8G 1:2A __________________________________________________________________ B-13
FIGURE B-8H 1:2B __________________________________________________________________ B-14
FIGURE B-8I 1:2C___________________________________________________________________ B-14
FIGURE B-8 ALERTS TAB_____________________________________________________________ B-15
FIGURE B-9 MILLITRON CHANNEL TUNING/CHANGING SCREENS _____________________________ B-16
FIGURE B-11 ADDRESS SCANNER SCREEN _______________________________________________ B-17
FIGURE F-1. INTERCONNECT DIAGRAM (OPTIONAL SW CONTROLLER)___________________________F-2
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List of Tables
TABLE 1-1. KA-BAND TWT AMPLIFIERS _________________________________________________1-1
TABLE 3-1 KA-BAND TWTA FRONT PANEL CONTROLS AND INDICATORS______________________3-3
TABLE 3-2. FRONT PANEL CONTROL KEYS_________________________________________________3-7
TABLE 3-3 LED GROUP AND DISPLAY DESCRIPTION_______________________________________3-8
TABLE 3-4. HELIX AND RF SETTINGS FAULT AND ALARM RANGES: 120W CW/250W PEAK_________3-15
TABLE 3-5. HELIX AND RF SETTINGS FAULT AND ALARM RANGES: 175W CW / 250W PEAK________3-16
TABLE 3-6. HELIX AND RF SETTINGS FAULT AND ALARM RANGES: 250W/275W CW______________3-17
TABLE 4-1. RF SWITCH PIN ASSIGNMENT (J5): 1:1 SWITCH OPTION _____________________________4-5
TABLE 4-2. DEFAULT CONFIGURATION-ETHERNET INTERFACE OPTION __________________________4-7
TABLE 4-3. ETHERNET INTERFACE PORT NUMBERS _________________________________________4-15
TABLE 6-1 PREVENTIVE MAINTENANCE PERFORMED BY OPERATORS _________________________6-2
TABLE 6-2 PREVENTIVE MAINTENANCE PERFORMED BY TECHNICIAN _________________________6-2
TABLE 7-1 DRAWINGS ______________________________________________________________7-1
TABLE C-1 REPLACEABLE PARTS _____________________________________________________ C-1
TABLE F-1. KA BAND TWTA DRAWINGS__________________________________________________F-3
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S-1
CHAPTER
Safety
S.1 Introduction
This chapter provides the following safety guidelines for personnel:
• High Voltage Equipment Operating Guidelines
• Microwave Radiation Operating Guidelines
• Physical Safety Guidelines
In addition to the above items addressed in this chapter, included by reference are the following
pertinent sections of the International Standard EN60215, Safety Requirements for Radio Transmitting
Equipment:
• Appendix D, “Guidance on Assessing the Competence of Personnel for Designation
as Skilled,” and also Sub-clause 3.1 of the Standard.
• Appendix E, “Guidance on Safety Precautions to be Observed by Personnel
Working on Radio Transmitting Equipment, “and also
Sub-clauses 3.2, 3.7, and 22.1 of the Standard.
S.2 High Voltage Equipment
S.2.1 Personnel Operating Guidelines
This guideline document presents operating practices for operators and technicians who work
with high voltage equipment. In the context of this discussion any voltage that is lethal is viewed
as "high voltage." Therefore, even prime power (100 to 480 V
AC
) is dangerous because prime
power potentials have been known to cause death or injury.
Electrical circuits operate quickly and do not allow a careless individual a second chance. When
dealing with high voltage, the results are very consistent and predictable. The hazards associated
with high voltage are always present. The fact that the control switch says OFF does not mean
you are safe. Many high voltage circuits are like loaded guns. In general, you cannot see a high
voltage hazard. You can learn to recognize situations that present a threat and how to avoid them.
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NOTE: THE GUIDELINES PRESENTED IN THIS DOCUMENT
ARE NOT ACADEMIC. THEY ARE BASED ON THE
EXPERIENCE OF ENGINEERS AND TECHNICIANS WHO
HAVE YEARS OF EXPERIENCE WITH HIGH VOLTAGE
CIRCUITS.
S.2.2 When is Voltage "High"?
As stated earlier, any voltage that will kill you should be treated as high voltage. Voltages
associated with prime power generally do not jump the air gap between people and the
equipment. Usually exposed circuit elements such as a terminal, bare piece of wire, or some non-
insulated surface must be touched.
One of the problems associated with prime power is that some equipment can be "floating" above
ground. In this case, if you place one hand on the equipment chassis and the other on earth
ground, you can be jolted, injured, or killed. 480VAC can stimulate an involuntary muscle response
that can literally throw you across a room or seize and hold you across the voltage terminals. 600
or more volts can hold you indefinitely. If the potential is sufficient to drive 200 milliamps through
your body you will be held indefinitely. Some people consider the 200 to 600 volt range to be
worse than potentials of thousands of volts.
S.2.3 General High Voltage Guidelines
In addition to the above, the following practices have proven effective for personnel who deal
with high voltage equipment.
a) Hands off. Avoid contact with any potential source of high voltage. Keep hands out of
the equipment when it is operating.
b) Avoid accidental contact. Make sure that some other part of your body does not come
in contact with the high voltage circuits. It is easy to forget the hazards when you are
concentrating on a frustrating or interesting task. Pens and badges in shirt pockets
could contact the equipment.
c) Never work on high voltage circuits when you are alone. If anything should happen
to you, your only chance may be prompt action by some other person. Be sure someone
else is present and knows what to do in any emergency (e.g., how to shut equipment
off, first aid, who to call, etc.)
d) Use one hand when working with high voltage circuits. Many people recommend
that you put one hand in your pocket when you use a probe or other piece of
equipment inside a high voltage section.
e) Do not float measuring equipment above ground. Make all measurements with
respect to ground. If you float an instrument, do not reach inside the equipment.
Although it is more difficult to get the right setup, it is well worth the effort.
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f) Do not assume that the level of risk is a function of size. Some large high power
voltage equipment looks docile. One reason the equipment is so big is to get the
proper separation between high voltage points. On the other hand, just because the
equipment is small is no assurance of safety. Dense packaging results in more difficult
access and increases the chance that you will accidentally hit the wrong point.
g) Always discharge high voltage capacitors. High voltage capacitors store a lot of
energy for long periods of time. High voltage capacitors also exhibit a "memory" in that
they can recover after discharge and reach lethal levels. In addition to the "memory"
problem, there have been instances where the built-in safety features have failed or
have been miswired. Each and every time you go to work on a piece of high voltage
equipment, use a discharge device with a long handle to discharge every high
voltage capacitor.
h) Do not depend on the automatic features of the equipment to save you. You never
know when someone has left a circuit disabled, if there has been a wiring error, or if a
component has failed.
i) Take personal responsibility to assure that no one can turn on the high voltage
circuits when you are working on the equipment. Precautions would include taping
down (or installing a keeper) on controls/circuit breakers and/or disconnecting the
power source to the high voltage circuits, activating interlocks that prevent high
voltage turn on, etc. Know where the disconnects are and use them. Do NOT rely on
anyone not to turn on the high voltage.
j) Set up your test equipment with the power off. Conduct the power-on operations
when you have your hands out of the equipment.
k) Do not use short probes for high voltage measurements. A short probe does not allow
any margin for error. If your hand slips you could accidentally come into contact with
a danger point. A long probe avoids the whole problem.
l) Read the instruction manual. The best insurance is foreknowledge of hazards.
m) Create a favorable environment for safe operations. This means that if people are
crowding you, stop the operation if it involves high voltage. Pressure can lead to
carelessness. In the same way, fatigue is also an enemy. STAY ALERT AT ALL TIMES
WHEN WORKING WITH HIGH VOLTAGE.
n) Do not become over-confident. Maintain a healthy respect for high voltage.
o) A good operating practice is to check the potential between the equipment chassis
and earth ground before you complete the circuit with your body. As voltage levels
increase, the protection you get from insulation and air gap diminishes. For example, in
a piece of equipment that involves beam voltages of about 16kV, the beam transformers
look very safe with massive insulation on the outside of the coils. Physical contact with
the beam coil when the system is operating can be fatal. Although the equipment is
placard to warn people of the presence of high voltage, it is virtually impossible to
placard every point of danger in a system.
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p) If you do not know how the equipment works and what the hazards associated with
the equipment are in specific terms, do NOT handle the equipment. The greatest
protection you can have when dealing with high voltage equipment is specific detailed
knowledge on that particular piece of equipment.
q) Avoid "haywire" test setups. It is easy to get in trouble if the setup you are using has a
jumble of wires.
r) Make sure your connections are secure. Do NOT allow leads to slip off and move
about in an uncontrolled fashion. Even if it is not one of the high voltage leads, a free
lead could (and generally does) move exactly to where you do not want it. The only
safe connection is a mechanically secure one.
s) Watch out for unterminated high voltage leads. Some connectors depend on circuit
loading to avoid arcing between closely spaced terminals. Unloaded high voltage lines
or plugs can lead to arcing situations.
t) Shut off the high voltage when you are making low voltage measurements. It does
not make sense to increase danger needlessly. While there may be times when you
cannot shut off the high voltage during a low voltage measurement, this is generally
not the case.
u) Remove the test equipment when you have finished a measurement program. There
have been many instruments destroyed or damaged because a test program was
conducted in a haphazard manner, rather than in an orderly progression from start to
finish. Experience has shown in many instances when a little order would have
prevented a tragedy or avoided an expensive mistake.
v) Be extremely wary when making filament voltage measurements. The cathode of
tubes is elevated above (or below) ground and the filament voltages usually cannot be
measured with reference to ground. Do everything you can to assure that the high
voltage cannot be turned on when you are making your measurements. This includes
disconnecting the high voltage drive source, shorting out appropriate leads, taping
down switches, and anything else you can think of to protect yourself.
w) When troubleshooting a unit, assume that the switches and components are
defective. You may shut off the high-voltage switch in some systems, but if the switch
were defective, the high voltage would still be on. Returned units are potential booby
traps.
x) Make sure that your workstation is stable. Flimsy work surfaces or supports for the
equipment or the test instruments represent a real threat. Do NOT use a setup that you
know is unstable and/or dangerous.
y) Use a 1-minute rule. Wait 1 minute or more after you have shut off the equipment
before you work on a unit. Part of the reason for a
1-minute rule is that some of the dielectrics (insulators) used for high voltage circuits
can store a charge. While the amount of charge stored is a function of the size of the
object, a 1-minute rule provides an additional margin of safety.
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z) Maintain a healthy respect for any kind of live circuit. Complacency can hurt or kill
you. Your continued wariness is your best insurance against injury or death.
S.3 Microwave Radiation
S.3.1 Personnel Operating Guidelines
This guideline presents operating practices appropriate for operators and technicians who work
with equipment involving microwave radiation. Keep in mind that levels of microwave radiation
that do not induce immediate physical discomfort in most individuals can be sufficiently high to
induce long term effects.
CPI Satcom Division equipment usually is related to amplification of a RF signal from an external
source. Even if a source is not connected to the amplifier you are working with, there are
situations where the amplifier can go into a self-induced mode and generate high levels of RF
energy. This condition can exist if the unit is operated with high voltage ON and without proper
termination on the input and output of the amplifier.
ELECTRICAL HAZARD! PROTECT YOURSELF AND THOSE
AROUND YOU FROM UNWANTED RF EXPOSURE. ALWAYS
TERMINATE THE AMPLIFIER INPUT AND OUTPUT WITH A RF
DUMMY LOAD BEFORE YOU TURN THE HIGH VOLTAGE ON.
THIS WILL REDUCE THE CHANCES OF OSCILLATION DUE TO
INTERNAL AMPLIFIER NOISE.
S.3.2 Microwave Discussion
Limit exposure to microwave radiation to prevent unwanted biological effects. There are other
effects that can lead to problems if you are careless in operating or servicing microwave
equipment. The permissible levels are quite low in comparison to the power levels of the
amplifiers built by CPI (e.g., less than 10 mW vs. 20 to 10,000 Watts delivered by different units)
Local radiation levels can be detected with the proper equipment. The permissible levels are
currently being studied by a number of organizations. In the past the U.S. Safety Codes
established a dosage rate of 10mW/Cm
2
. Recently the permissible level has been reduced to 1
mW/Cm
2
. in the United States, as has been the case in several European countries.
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S.3.3 General Microwave Guidelines
The purpose of these guidelines is to provide practical approaches to control unwanted
microwave energy associated with the operation and servicing of CPI Satcom Division equipment.
The following approaches are effective in both laboratory or field environments:
a. Always terminate the output waveguide or coaxial connector with a dummy
RF load (capable of dissipating full CW RF power). Similarly, terminate the
input to avoid the possibility of the amplifier being driven by stray leakage
signals. Incorporate the terminations prior to applying prime power to the
amplifier. This procedure prevents self-oscillation and irradiation of the local
equipment.
b. Do not look into the output port of the powered RF amplifier. Treat the
powered amplifier as though it is a loaded gun. Your eyes are particularly
vulnerable parts of your body.
c. Shut off the unit if you are trying to locate a RF leak. As noted earlier, the
levels of concern are very low. Examine the physical unit with the high voltage
OFF. If you have to survey the RF runs with the power ON to find the leaky
joint or component, start by testing the system with low RF input and a
radiation meter.
If the microwave radiation exceeds 0.5mw/cm. sq., shut OFF the high power
voltage and consult your supervisor. Work quickly (not at a panic pace) to
minimize the dose level. The dose you get is directly proportional to the power
level and the time you are exposed. Exposure to microwave radiation can
induce both thermal and non-thermal biological effects, especially with the
eyes. If you damage the lens of your eyes by exposure to microwave radiation,
cataracts can result. Consider that small microwave ovens are very effective in
cooking foods. If you follow these guidelines you can minimize exposure of
yourself and other people in the operations that you control.
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S.4 Physical Safety
S.4.1 Lifting Heavy Objects
Back and other injuries can result from one person trying to lift too much weight.
Use extreme caution when lifting the klystron. Klystrons weigh up to 100 pounds (45 kg) and
require two persons to lift them.
Due to the weight of the drawers, at least two persons are required for installation of the drawers
to the final rack assembly. At least two people are also required for removal of the drawers from
the rack assembly.
S.4.2 Extending Rack Slides
1. Serious injuries can result from heavily loaded racks or drawers falling forward.
Due to the weight of the drawers, the rack must be securely bolted to the floor in all four
corners to prevent tipping when the drawer slides are extended.
Verify that all slides are securely mounted and that all latches and stops are functioning
properly.
2. Serious injuries can also result from hands, fingers, or clothing getting caught in slides and
drawers when extended drawers are being pushed back into a rack.
Exercise extreme caution when sliding extended drawers back into a rack.
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1-1
CHAPTER 1
Introduction
1.1 Overview
The CPI Ka-Band TWTA (Traveling Wave Tube) ODU Amplifiers are designed for satellite
communication earth stations, satellite newsgathering vehicles, and flyaway applications. The key
feature of these amplifiers permits direct mounting to antenna structures, thereby eliminating
transmission line losses encountered in conventional remotely mounted arrangements. For this
reason, these amplifiers are referred to as “ Ka-Band TWT Amplifiers.”
Table 1-1 shows the model numbers, frequency ranges, and power outputs of these amplifiers.
Figure 1-1 is a photograph of a Ka-Band TWT Amplifier. All models have the same appearance.
Table 1-1. Ka-BAND TWT Amplifiers
Model Number Frequency Range
(GHz) Rated Power (Watts)
T02KO 27.5 to 31.0 GHz 250W Peak
T03KO 27.5 to 31.0 GHz 250W CW
By industry convention, the rated power of an amplifier is the output power of the high power-
amplifying component, a traveling wave tube (TWT). The output power available to the user at
the amplifier output flange is lower. Peak power amplifiers offer the same linear power as their
CW (Continuous Wave) counterparts, except their rated CW power is typically 1.5 to 3dB below
their peak rating. Depending on model selected, the operating frequency range and rated CW
power level will vary.
D OC .01031492 R EV .3
1-1

KA BAND OUTDOOR TWT AMPLIFIER
1-2
Figure 1-1. Ka-Band TWTA (Front View)
The Ka-Band TWTAs operate with AC input (line) voltages of 100 - 240 ± 10% V
AC
at any
frequency between 47 and 63 Hz.
All of the Ka-Band TWTAs are the same size and nearly the same weight. The typical model
weighs 52 pounds (23.6 kg.), the overall dimensions, excluding switches, connectors, and handles
and mounting brackets, are 10.25 by 9.5 by 20.0 inches (260.4 X 508 X 241.3 mm).
These amplifiers are air-cooled. The cooling air enters the bottom of the unit and exits the rear
end. A feature standard in Ka Band TWTAs regulates the fan speed control, using a sensor to vary
the speed with TWT temperature. This greatly increases the fan life while reducing acoustical
noise. (See Chapter 2 for more details.) Care should be taken to ensure the airflow path is not
blocked. If the amplifier is to be powered up on a test bench, then it should be set on blocks or
mounting brackets to prevent airflow blockage. Ka-Band TWTAs can operate in direct sunlight at
ambient temperatures ranging from –40 to + 60°C.
Detailed specifications for the Ka-Band TWTAs ODU are provided in Chapter 7, "Drawings”.
INSTALLATION AND OPERATION MANUAL